System and method for evaluating the performance of a pump

ABSTRACT

Systems and methods to determine the apparent density of a fluid being displaced by a pump. The apparent density may be determined by comparing an expected torque of the pump to an actual torque of the pump. The apparent density can also be used to detect irregular operating conditions.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/089,546, filed Apr. 19, 2011.

BACKGROUND OF THE INVENTION

The present invention relates generally to evaluating the performance ofa pump, and more particularly to systems and methods using sensormeasurements to determine the performance of a pump in an ebullatedreactor.

Hydrocracking is a chemical process used in the petroleum industry torefine crude oil into usable products such as gasoline, diesel fuel, andother forms of petroleum-based products. In general, crude oil containslarge hydrocarbon molecules that have high boiling points and are notdesirable in many industrial applications. Hydrocracking utilizespressure, temperature, and catalysts to break down the largerhydrocarbons into smaller, more usable molecules (e.g., gasoline,kerosene, etc.). Numerous hydrocracking techniques have been developedover the years and a number of refinery designs have developed, as aresult.

In many oil refinery designs, one or more ebullated reactors are used aspart of the hydrocracking process. Ebullated reactors are typically in atower configuration and operate by boiling unrefined oil in a catalystand adding hydrogen. As hydrocracking occurs, liquid and/or vaporcontaining lower molecular weight hydrocarbons are produced. These lowermolecular-weight hydrocarbons are then siphoned off from the ebullatedreactor for separating into their respective petroleum products.

Specialized pumps known as ebullating pumps are used within ebullatedreactors to recirculate the hydrocarbons and catalyst within thereactors. Hydrocracking catalysts are typically solids that may settleto the bottom of an ebullated reactor over time. In order to preventthis, an ebullating pump provides flow recirculation for the ebullatedreactor that maintains the catalyst within a certain area of theebullated bed. Typically, an ebullating pump takes the clean chemicalproduct from the top of the reactor and recirculates it back through thebottom of the reactor. This action creates a flow of fluid upward insidethe reactor, thereby forcing catalyst-heavy fluid above a desired level.Without such fluid motion, catalyst may deposit inside the pump assemblyand diminishing the pump's performance.

As the “heart” of an ebullated reactor, the performance of an ebullatingpump is key to the hydrocracking process. Maintenance of an ebullatingreactor is often difficult and costly, meaning that the early detectionof performance degradation in its ebullating pump may be used to preventmore serious repairs to the entire reactor. However, it remainschallenging to devise systems and methods that evaluate the performanceof an ebullating pump.

SUMMARY OF THE PRESENT INVENTION

In one embodiment, a method for determining an apparent density of afluid being displaced by a pump having a motor is disclosed. The methodincludes receiving, at a computer, sensor data indicative of thevoltage, current, and temperature of the motor. The method also includesdetermining an expected torque value for the pump using the sensor data,determining an actual torque for the pump using the sensor data, andusing the expected torque and actual torque to determine an apparentdensity of the fluid. The method further includes using the apparentdensity to detect an irregular operating condition and generating analert if an irregular operating condition is detected.

In another embodiment, a pump monitor is disclosed. The pump monitorincludes an interface configured to receive sensor data from a voltagesensor, current sensor, and temperature sensor connected to a motor of apump. The pump monitor also includes a processor and a non-transitorymemory connected to the processor. The memory stores instructions that,when executed by the processor, cause the processor to determine anexpected torque value for the pump using the sensor data, determine anactual torque for the pump using the sensor data, and use the expectedtorque and actual torque to determine an apparent density of the fluid.The instructions further cause the processor to use the apparent densityto detect an irregular operating condition and to generate an alert ifan irregular operating condition is detected.

In yet another embodiment, an ebullating pump system is disclosed. Theebullating pump system includes an ebullating pump having a motor andsensors connected to the motor that measure the voltage, current, andtemperature of the motor. The system also includes a pump monitor thatreceives sensor data from the sensor. The pump monitor storesrelationship data in a memory that relates the speed of the pump totorque. The pump monitor also utilizes a processor to determine anexpected torque using the sensor data and the relationship data, todetermine an actual torque for the pump by using the sensor data, and todetermine an apparent density of the fluid by using the expected torqueand actual torque. The pump monitor further uses the apparent density todetect an irregular operating condition and generates an alert if anirregular operating condition is detected.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments can be bestunderstood when read in conjunction with the following drawings, wherelike structure is indicated with like reference numerals and in which:

FIG. 1 is a schematic illustration of an ebullating reactor, accordingto an aspect of the present invention;

FIG. 2 is a schematic illustration of a pump motor for an ebullatingpump, according to an aspect of the present invention; and

FIG. 3 is a flow diagram of a method for detecting irregular operatingconditions in an ebullated reactor, according to an aspect of thepresent invention.

The embodiments set forth in the drawings are illustrative in nature andare not intended to be limiting of the embodiments defined by theclaims. Moreover, individual aspects of the drawings and the embodimentswill be more fully apparent and understood in view of the detaileddescription that follows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As stated above, it is challenging and difficult to devise systems andmethods that evaluate the performance of an ebullating pump. Maintenanceof an ebullating reactor requires specialized machinery and may stop theproduction of refined petroleum while the maintenance is beingperformed. While sensors within the reactor may provide additionalinformation about the state of the system, each sensor is also anotherpotential point of failure for the reactor. The present inventors haverecognized the need for systems and methods that evaluate theperformance of an ebullating pump while minimizing the number of sensorsneeded for the evaluation.

Referring now to FIG. 1, ebullated reactor 100 is shown, according toembodiments shown and described herein. Ebullated reactor 100 contains amixture 102 that may contain hydrocarbons, hydrogen, catalyst, and otherchemicals in the form of a liquid and/or gas. Unprocessed hydrocarbonsare fed into ebullated reactor 100 via raw feed inlet 104. Similarly,hydrogen gas is also fed into ebullated reactor 100 via hydrogen inlet106.

Ebullated reactor 100 performs hydrocracking by heating the suppliedfeed, hydrogen, and catalyst to temperatures that can range upwards of900° F. or more under pressure. As the hydrogen and raw feed combine,the fluid/gas mixture passes distributor 114 and is forced upwardsthrough vessel 101. A zeolite-based catalyst or other knownhydrocracking catalyst causes the heated fluid-catalyst mixture tochemically break down the larger hydrocarbons into smaller hydrocarbons.The fluid 118 containing the broken-down hydrocarbons is then passedfrom ebullating reactor 100 via outlet 116 to a separator that separatesout the different, smaller hydrocarbons contained within fluid 118(e.g., gasoline, kerosene, etc).

Because the catalyst used for hydrocracking is typically a solid, thecatalyst tends to settle within ebullated reactor 100 over the course oftime. Ebullating pump 110 prevents the catalyst from settling byconstantly recirculating fluid 118 within vessel 101. Suction isprovided at pump intake 112, where fluid 118 is forced towards thebottom of ebullated reactor 100 by ebullating pump 110. Ebullating pump110 then forces fluid 118 through pump outlet 108, thereby creating anupward fluid motion within ebullated reactor 100. In some embodiments,the fluid received by pump intake 112 is also reheated as part of therecirculation process. In this way, catalyst-heavy fluid is maintainedbetween expanded catalyst level 122 and settled catalyst level 120within ebullated reactor 100.

Although ebullating pump 110 is shown as being external to ebullatedreactor 100, it is to be understood that this is merely exemplary andthat ebullating pump 110 may be located in any number of locationsinside or external to the main housing of ebullated reactor 100.Ebullating pump 110 may be of any number of submersible ornon-submersible pump designs suitable for recirculating fluid throughoutebullated reactor 100. In some embodiments, ebullating pump 110 may alsobe a centrifugal pump or any other type of dynamic pump. In otherembodiments, ebullating pump 110 may be a positive displacement pump.

Two irregular operating conditions may lead to performance degradationin ebullated reactor 100. First, a catalyst carryover condition mayoccur when the catalyst levels within ebullated reactor 100 are notmaintained correctly. Catalyst that settles to the bottom of ebullatedreactor 100 may clog ebullating pump 110 and must be withdrawn andrecycled. Second, a gas entrainment condition may occur when thehydrogen levels are not maintained properly, leading to a build-up ofhydrogen at the top of ebullated reactor 100. Early detection of suchirregular operating conditions helps to prevent unnecessary wear oncomponents and to ensure the proper operation of ebullated reactor 100.

Both gas entrainment and catalyst carryover may be detected using theapparent density of the medium displaced by pump 110. If the apparentdensity is greater than expected, additional catalyst may be present inthe medium, indicating catalyst carryover. Conversely, if the apparentdensity is less than expected, additional hydrogen may be present in themedium, indicating gas entrainment. As both conditions are undesirablewithin ebullated reactor 100, detection of either condition by a pumpmonitor thereby allows an operator to take corrective measures.

Referring now to FIG. 2, a schematic illustration of a pump motor for anebullating pump is shown, according to embodiments shown and describedherein. Pump motor 202 provides mechanical power to force catalyst-heavyfluid to recirculate within an ebullated reactor. In variousembodiments, pump motor 202 may be an alternating current (AC) or directcurrent (DC) motor that receives electrical power and converts it tomechanical power. In other embodiments, pump motor 202 may also includea variable frequency drive (VFD) that allows the speed of the motor tobe varied. Variation of the speed of pump motor 202 may be used tocontrol the flow rate and other characteristics of the fluid beingpumped by the motor.

Pump motor 202 may include a number of sensors to monitor theperformance of the pump and the ebullated reactor as a whole. Voltagesensor 204 measures one or more voltages supplied to pump motor 202.Current sensor 206 measures one or more electrical currents supplied toand/or returned from pump motor 202. Temperature sensor 208 measures thetemperature of pump motor 202. Where pump motor 202 includes a VFD,frequency controller 210 also tracks the operating frequency used by theVFD to control the operation of pump motor 202. Sensors 204, 206, and208 may be any number of sensors or configurations to measure thevoltages, currents, and temperatures associated with pump motor 202. Forexample, temperature sensor 208 may be a single temperature sensor,while voltage sensors 204 and current sensors 206 may be a combinedintegrated circuit that measures both voltage and current. It should beappreciated that any number of different combinations of sensors andsensor configurations may be used, without deviating from the principlesor teachings of the present disclosure.

Bus lines 212, 214, 216 and 218 connect frequency controller 210 andsensors 204, 206, and 208 to computing device 220, which monitors andevaluates the performance of the ebullating pump and ebullated reactor.Bus lines 212, 214, 216 and 218 may be any combination of hardwired orwireless connections. For example, bus line 214 may be a hardwiredconnection to provide voltage readings to computing device 220, whilebus line 216 may be a wireless connection to provide current readings tocomputing device 220. In some embodiments, bus lines 212, 214, 216, and218 are part of a shared data line that conveys voltage, current,temperature and frequency values to computing device 220. In yet otherembodiments, bus lines 212, 214, 216 and 218 may include one or moreintermediary circuits (e.g., other microcontrollers, signal filters,etc.) and provide an indirect connection between sensors 212, 214, 216and computing device 220. In yet further embodiments, computing device220 may operate as a VFD for pump motor 202 and locally includesfrequency controller 210.

Interface 222 is configured to receive the sensor data from sensors 204,206 and 208 via bus lines 212, 214, and 216 and frequency data fromfrequency controller 210 via bus lines 218. For example, interface 222may include one or more wireless receivers, if any of lines 212, 214,216, or 218 are wireless connections. Interface 222 may also include oneor more wired ports, if any of lines 212, 214, 216, or 218 are wiredconnections. Interface 222 may also include circuitry configured todigitally sample or filter the sensor data from bus lines 212, 214 and216. For example, interface 222 may sample the current data receivedfrom current sensors 206 via bus line 214 at discrete times (e.g., k,k+1, k+2, etc.) to produce discrete current values (e.g., I(k), I(k+1),I(k+2), etc.).

Computing device 220 is shown to include processor 230, which may be oneor more processors communicatively coupled to memory 232 and interfaces222 and 224. Memory 232 may be any form of memory capable of storingmachine-executable instructions that implement one or more of thefunctions disclosed herein, when executed by processor 230. For example,memory 232 may be a RAM, ROM, flash memory, hard drive, EEPROM, CD-ROM,DVD, other forms of non-transitory memory devices, or any combination ofdifferent memory devices.

Interface 224 may provide one or more wired or wireless connectionsbetween computing device 220 and other computer and electronic devicesin a manner similar to interface 222. Computing device 220 maycommunicate with other computer systems 252 (e.g., another computer, aportable electronic device, a server, etc.) via interface 224. Computingdevice 220 may also communicate with interface devices 254 (e.g., adisplay, a touch screen, a keyboard, a mouse, etc.) which allowscomputing device 220 to convey and receive information from a user. Insome embodiments, computing device 220 may also receive sensor data fromother sensors 256 located in or near the ebullated reactor (e.g., anexternal temperature sensor, an internal temperature sensor, catalystdensity detectors located within the ebullated reactor, etc.).

Memory 232 includes parameters 250 which may be preloaded onto computingdevice 220 or received from other computing devices 252 or frominterface devices 254 via interface 224. Parameters 250 include datavalues that control one or more operations of computing device 220. Forexample, parameters 250 may include a setting that causes computingsystem 220 to send one or more alerts (e.g., an email, an automatedtelephone call, a text message, etc.) to other computer systems 252 whenone or more conditions are met. In another example, parameters 250 mayinclude threshold values that define one or more ranges for data valueswhen pump motor 202 is operating normally.

Memory 232 also includes rotor friction model 246 and equivalent circuitmodel 248. Rotor friction model 246 models the amount of friction andother factors relevant to the mechanical operation of pump motor 202 andthe ebullating pump. Equivalent circuit model 248 provides a simplifiedcircuit model that simulates the electrical operation of pump motor 202.In some embodiments, rotor friction model 246 and equivalent circuitmodel 248 may be preloaded into memory 232, while in other embodiments,they may be received from other computing systems 252 and/or frominterface devices 254.

Memory 232 also includes winding temperature analyzer 238, which usesequivalent circuit model 248, current data from current sensor 206, andtemperature data from temperature sensor 208 to estimate a temperatureof the windings of the pump. Since direct measurement of the windingtemperature of pump motor 202 is often difficult, winding temperatureanalyzer 238 estimates the winding temperature indirectly. Equivalentcircuit model 248, for example, may treat the windings of pump motor 202as a resistive load. As current increases through the windings, thetemperature of the windings also increases. As the temperature of thewindings increases, the resistance of the windings also decreases. Whenpump motor 202 is inactive and cooled down, winding temperature analyzer238 stores temperature measurements from temperature sensor 208 and usesthe electrical sensor measurements and equivalent circuit model 248 todetermine the resistance of the windings. When pump motor 202 has beenin operation for an amount of time, similar temperature measurements andresistance calculations are made by winding temperature analyzer 238. Ifthe windings of pump motor 202 are copper, winding temperature analyzer238 may utilize the following equation:

$T_{w} = {T_{oil} + {\Delta \; T_{n}*\left\lbrack \frac{I_{1}}{I_{2}} \right\rbrack^{2}} + \left\lbrack {1 + \frac{T_{w} - T_{n}}{T_{n} + 234.5}} \right\rbrack}$

where T_(w) is the winding temperature in Celsius, T_(oil) is theambient oil temperature surrounding the windings in Celsius, I₁ is theoperating current, T_(n) is the nominal operating temperature, ΔT_(n) isthe nominal temperature rise, and I_(n) is the nominal current. Once thewinding temperature is known, the winding resistance may be changedusing the relationship between winding resistance and temperature andused to update equivalent circuit model 248 for pump motor 202.

Thrust analyzer 236 uses voltage measurements from voltage sensor 204,current measurements from current sensor 206, parameters 250, and/orfrequency values from frequency controller 210 to calculate theoperating thrust of the ebullating pump. For example, thrust analyzer236 may perform one or more diagnostic tests and may calculate the speedof pump motor 202 in RPMs, to determine the hydraulic thrust of theebullating pump. Thrust analyzer 236 may use the determined hydraulicthrust, manufacturer information stored in parameters 250 (e.g.,rotating element weight, etc.), and injection oil thrust to determinethe operating thrust of the ebullating pump. In one embodiment, theoperating thrust F_(b) may be calculated as follows:

$F_{b} = {{F_{ref}*\frac{\rho_{app}}{\rho_{ref}}*\left\lbrack \frac{N_{m}}{N_{ref}} \right\rbrack^{2}} + {F_{q}*\left\lbrack \frac{q}{q_{n}} \right\rbrack^{2}} + F_{w}}$

where ρ_(app) is an apparent density of the medium being displaced bythe pump (e.g., from apparent density analyzer 242), ρ_(ref) is theexpected fluid density (e.g., a reference value stored in parameters250), N_(m) is the operating speed of pump motor 202 (e.g., which may bederived using the voltage, current, and/or frequency values), F_(w) isthe dead weight load of the rotor of pump motor 202 (e.g., stored inparameters 250), F_(ref) is the test hydraulic thrust, N_(ref) is thetest speed, F_(q) is the nominal oil injection thrust, q is the oilinjection flow rate, and q_(n) is the nominal oil injection flow rate.

Torque analyzer 234 determines the slip and developed torque of pumpmotor 202. To determine the developed torque and slip of pump motor 202,torque analyzer 234 may use inputs such as the frequency from frequencycontroller 210, voltage and current measurements from sensors 204, 206,and stored parameters 250 (e.g., data values provided by themanufacturer of pump motor 202 and set using the no-load, locked rotorand winding tests of the motor). Torque analyzer 234 uses the inputswith equivalent circuit model 248 to determine the slip and thedeveloped torque of pump motor 202. Torque analyzer 234 may also use thefrequency input and the previously determined slip to determine therunning speed of pump motor 202 for additional processing (e.g., as usedby thrust analyzer 236).

Torque analyzer 234 also determines the net motor output torque of pumpmotor 202. For example, if the ebullating pump is a submersible pump,fluid viscosity and rotational friction losses may also be significant.Torque analyzer 234 may use the temperature measurements fromtemperature sensor 208, rotor friction model 246, the determined runningspeed of pump motor 202, and parameters 250 (e.g., data valuescorresponding to the no-load testing of pump motor 202) to determine theviscosity and rotational friction losses for pump motor 202 when it isin use. Torque analyzer 234 may then determine the net output torque ofpump motor 202 by calculating the difference between the developedtorque and the rotational losses.

In some embodiments, torque analyzer 234 may also generate or maintainone or more torque-speed relationships and store the related informationin parameters 250 (e.g., as a table, database, bitmap, curve, etc.) forlater use. In such a case, one or more sets of speed-torquerelationships may be stored for different temperatures and frequencies.For example, because the winding resistance in equivalent circuit model248 may vary with temperature, different speed-torque curves may also bestored to account for the different temperatures.

Apparent density analyzer 242 compares expected torque values and thenet output torque values determined by torque analyzer 234 to estimatethe apparent density of the fluid passing through the ebullating pump.For example, torque analyzer 234 may determine one or more referencetorque and density parameters during a diagnostic run of the ebullatedbed and store them in parameters 250. In this way, apparent densityanalyzer 242 may utilize the relationship between the torque and fluiddensity to estimate the apparent density of the fluid. In oneembodiment, apparent density analyzer 242 uses the following equation todetermine the apparent density:

$\rho_{app} = {\rho_{ref}*\frac{\tau_{0}}{\tau_{ref}}}$

where ρ_(app) is the apparent density, ρ_(ref) is the expected fluiddensity (e.g., a reference value stored in parameters 250), τ_(ref) isthe expected torque on the pump based on the current operating speed,and), τ₀ is the operating torque determined by torque analyzer 234.

Apparent density analyzer 242 may also use the estimated apparentdensity values to detect irregular operating conditions within theebullated reactor. A higher than normal apparent density indicates acatalyst carryover condition (e.g., there is more than expected catalystpresent within the fluid). Conversely, a lower than normal apparentdensity indicates gas entrainment (e.g., there is a higher than expectedamount of gas present within the fluid). When either condition isdetected, apparent density analyzer 242 may initiate one or morediagnostic routines (e.g., by altering one or more operating parametersof the ebullated bed and/or pump motor 202) and may provide one or morealerts to other computer systems 252 or to interface devices 254. Insome embodiments, the alert may be sent automatically. For example,apparent density analyzer 242 may send a text message to other computersystems 252 (e.g., a laptop, a cellular phone, etc.) or provide indiciaof the condition to interface devices 254 (e.g., as an alert on adisplay, etc.), in order to alert a user. In other embodiments, apparentdensity analyzer 242 may cause the alert to be stored in memory 232and/or other computer systems 252 for later use. For example, lowerpriority alerts may be presented to a display only after receiving arequest for information about the alerts.

Apparent density analyzer 242 may further determine the volume fractionof gas, oil, and catalyst inside the ebullated reactor. In this case,other sensors 256 may include one or more catalyst density sensorslocated within the ebullated reactor. Apparent density analyzer 242 mayreceive the catalyst density measurements and use them with theestimated apparent density values to determine the volume fraction ofgas, oil, and catalyst inside the ebullated reactor. Apparent densityanalyzer 242 may then provide the volume fraction values to othercomputer systems 252 and/or to interface devices 254 via interface 224.

Lifespan estimator 244 uses the torque values from torque analyzer 234,thrust values from thrust analyzer 236, winding temperatures fromwinding temperature analyzer 238, apparent density values from apparentdensity analyzer 242, and/or volume fraction values from apparentdensity analyzer 242 to estimate component lifetimes for the ebullatedreactor. For example, if the winding temperature determined by windingtemperature analyzer 238 is above an acceptable threshold, lifespanestimator 244 may adjust the lifespan estimation of pump motor 202downward. Initial lifespan estimates may be provided by other computersystems 252, interface devices 254, or preloaded into parameters 250.Lifespan estimator 244 also stores and retrieves one or more operatingtime parameters in parameters 250 that denote the amount of time that acomponent in the ebullated reactor has been in use. As a component isused, its operating time is subtracted from its initial lifespanestimate by lifespan estimator 244 and adjusted for any conditions thatmay lead to premature wear (e.g., using the winding temperatures,apparent densities, etc., determined by computing device 220), therebydetermining an estimate of the remaining lifetime of the component.

Lifespan estimator 244 also includes one or more reporting features andprovides reports to other computer systems 252 and/or to interfacedevices 254. For example, a plant operator using interface devices 254may view the torque values, thrust values, apparent density values, etc.in real time or near real-time. In some embodiments, lifespan estimator244 may also store one or more data values that it receives to provide ahistory of the data values. For example, lifespan estimator 244 maystore the apparent density values from apparent density analyzer 242over a period of time and generate one or more charts that relate theapparent density values as a function of time. Lifespan estimator 244may then provide the chart to other computer systems 252 and/or tointerface devices 254.

Referring now to FIG. 3, a method for detecting irregular operatingconditions in an ebullated reactor is shown, according to an exemplaryembodiment. Irregular operating conditions include, but are not limitedto, gas entrainment conditions and catalyst carryover conditions withinthe ebullated reactor. Other irregular operating conditions may be anyoperating condition that may be detected using the apparent density ofthe fluid being displaced by the pump.

Method 300 includes determining an expected torque value for anebullating pump associated with the ebullated reactor (block 302). Theebullating pump recirculates catalysts and hydrocarbon-containing liquidand/or gas throughout the ebullated reactor. A pump hydraulicperformance test may be used at a time in which the ebullated reactor isoperating normally to determine one or more baseline torque values andstore these values within an electronic memory for future use. Thesebaseline torque values may then be used as expected torque values, sincethey correspond to the normal operation of the ebullated reactor.

Method 300 also includes determining an actual torque value for the pump(block 304). When the pump is in operation (e.g., the ebullated reactoris performing hydrocracking), data associated with the pump's motor maybe used by a processor to determine the actual torque for the pump. Ingeneral, the actual torque for the pump may be determined by subtractinga developed torque value by rotational losses. An equivalent circuitmodel for the motor may be used with the data associated with the motorto determine the motor's slip and developed torque. A frequency valuefor the motor and the determined slip can then be used to determine themotor's running speed. A rotor friction model may then be used with therunning speed and a temperature-dependent viscosity value to determinethe rotational losses. The actual torque can then be determined as thedifference between the developed torque value and the rotational losses.

Method 300 further includes determining an apparent density of themedium displaced by the pump by comparing the expected and actual torquevalues (block 306). For example, the apparent density may be determinedby multiplying an expected density by the ratio of operating torque toan expected torque. In other embodiments, the amount of rotationallosses may be used against a reference value to determine the apparentdensity.

Method 300 yet further includes using the apparent density to detectirregular operating conditions within the ebullated reactor (block 308).If the apparent density is lower than expected, this may indicate a gasentrainment condition (e.g., a higher than normal amount of gas bubblespresent within the fluid). Because gasses tend to have lower densitiesthan that of liquids and solids, a larger amount of gas present in thefluid would lower the fluid's apparent density. If the apparent densityis higher than expected, this may indicate catalyst carryover (e.g., ahigher than normal amount of catalyst present within the fluid and mayleave the ebullated reactor with the processed hydrocarbons). Catalystcarryover is undesirable because it increases the amount of impuritiesin the fluid leaving the reactor and also increases costs, sinceadditional catalyst would need to be added to the reactor.

Method 300 additionally includes generating an alert if an irregularoperating condition is detected (block 310). Any number of computerizedalerts may be generated to convey information about the irregularcondition. For example, an alert may be sent automatically to aninterface device to convey the alert to a user (e.g., a textual message,indicia on a display, an audio alert, etc.). In another example, thealert may be sent to another computing device (e.g., a server, datacollection device, etc.) that stores the alert for later recall.

Many modifications and variations of embodiments of the presentinvention are possible in light of the above description. Theabove-described embodiments of the various systems and methods may beused alone or in any combination thereof without departing from thescope of the invention. Although the description and figures may show aspecific ordering of steps, it is to be understood that differentorderings of the steps are also contemplated in the present disclosure.Likewise, one or more steps may be performed concurrently or partiallyconcurrently. While the above-described embodiments are shown inconnection with an ebullated reactor, this is to be understood asexemplary only. The systems and methods described herein may be usedwith any number of different pumping systems and pump designs.

The various operations of the methods and systems in the presentdisclosure may be accomplished using one or more processing circuits.For example a processor may be an ASIC, a specific-use processor, or anyexisting computer processor. One or more steps or functions in thepresent disclosure may also be accomplished using machine-readableinstructions and data structures stored on non-transitory,machine-readable media. For example, such media may comprise a floppydisc, CD-ROM, DVD-ROM, EEPROM, flash memory, or any other medium capableof storing the machine-executable instructions and data structures andcapable of being accessed by a computer or other electronic devicehaving a processor.

What is claimed is: 1.-20. (canceled)
 21. A pump system for anebullating reactor, the pump system comprising: an ebullating pumpcomprising: an intake for receiving a fluid comprising a liquidhydrocarbon raw material, a hydrogen gas additive and a catalyst; amotor; and; an outlet fluidly cooperative with the input such that uponoperation of the motor, the pump recirculates the fluid through theebullating reactor, sensors connected to the motor that measure at leastone of voltage, current, and temperature of the motor; and a pumpmonitor comprising a computing device with a processor and anon-transitory memory cooperative with one another to operate onparameters contained within the non-transitory memory as well as oncomputer readable and executable instructions comprising: a rotorfriction model to identify an amount of rotational friction lossespresent within the motor during operation thereof; an equivalent circuitmodel to simulate electrical operation of the motor; a windingtemperature analyzer cooperative with the sensors and the equivalentcircuit model to estimate a pump ending temperature; a thrust analyzercooperative with the sensors and parameters to calculate an operatingthrust of the ebullating pump; a torque analyzer cooperative with thesensors, the rotor friction model, the equivalent circuit model and theparameters to determine at least one of an actual torque and anoperating speed of the motor during operation thereof; an apparentdensity analyzer cooperative with the sensors, parameters and torqueanalyzer to: estimate the apparent density of the fluid passing throughthe ebullating pump; detect an irregular operating condition in the formof one or the other of a catalyst carryover condition and a gasentrainment condition; and generate a computerized upon detection of anirregular operating condition of the pump.
 22. The pump system of claim21, wherein the actual torque comprises a difference between a developedtorque and the rotational friction losses.
 23. The pump system of claim21, wherein the thrust analyzer may perform at least one diagnostic teston the ebullating pump.
 24. The pump system of claim 21, wherein theapparent density analyzer further determines a volume fraction of gas,oil and catalyst inside the ebullated reactor.
 25. The pump system ofclaim 21, further comprising a lifespan estimator cooperative with thetorque analyzer, the thrust analyzer, the winding temperature analyzerand the apparent density analyzer to estimate lifetimes for a pluralityof components that make up the ebullated reactor.
 26. The pump system ofclaim 21, wherein the actual torque is determined by calculatingrotational losses using the sensor data indicative of the temperature ofthe motor.
 27. The pump system of claim 21, wherein the ebullating pumpis a submersible pump.
 28. The pump system of claim 21, wherein thecomputer readable and executable instructions are contained within thenon-transitory memory.
 29. The pump system of claim 21, wherein theparameters are selected from the group consisting of data values thatcontrol one or more operations of the computing device and thresholdvalues that define one or more ranges for data values during operationof the motor.
 30. The pump system of claim 21, wherein the apparentdensity analyzer further may initiate one or more diagnostic routines(e.g., by altering one or more operating parameters of the ebullated bedand/or pump motor 202)
 31. The pump system of claim 21, wherein the thealert is sent automatically by the apparent density analyzer.
 32. Amethod of operating a pump in an ebullated reactor, the methodcomprising: introducing a petroleum-based fluid and ahydrogen-containing gas into the reactor; using the pump to circulate atleast the petroleum-based fluid through a catalyst bed that is disposedwithin the reactor; receiving sensor data indicative of at least one ofoperating parameter of a pump motor that provides mechanical power tothe pump during circulation of the petroleum-based fluid; and using apump monitor to execute computer readable instructions comprising: arotor friction model to identify an amount of rotational friction lossespresent within the motor during operation thereof; an equivalent circuitmodel to simulate electrical operation of the motor; a windingtemperature analyzer cooperative with the sensors and the equivalentcircuit model to estimate a pump ending temperature; a thrust analyzercooperative with the sensors and parameters to calculate an operatingthrust of the ebullating pump; a torque analyzer cooperative with thesensors, the rotor friction model, the equivalent circuit model and theparameters to determine at least one of an actual torque and anoperating speed of the motor during operation thereof; an apparentdensity analyzer cooperative with the sensors, parameters and torqueanalyzer to: estimate the apparent density of the fluid passing throughthe ebullating pump; detect an irregular operating condition in the formof one or the other of a catalyst carryover condition and a gasentrainment condition; and generate a computerized upon detection of anirregular operating condition of the pump.
 33. The method of claim 32,wherein the computer readable instructions are contained on a computingdevice with a processor and a non-transitory memory that are signallycooperative with the pump monitor.
 34. The method of claim 32, whereinat least one of the rotor friction model and the equivalent circuitmodel are received from a remote computing system.
 35. The method ofclaim 32, wherein at least one of the rotor friction model and theequivalent circuit model are received through an interface device.